Arch and wall construction



pril 12, 19491. I P, WRlGHT 2,467,069

ARCH AND WALL CONSTRUCTION Filed March 9, 1944 v 3 Sheets-Sheet 1 April 12, 1949. P. WRIGHT ARCH AND WALL :coNsTRUc'T-ION Filed March 9, 1944 3 Sheets-Sheet 2 :NVENTOR April 12, 1949. P. WRIGHT 2,467,069

ARCH AND WALL CONSTRUCTION Filed March 9, 1944 :sheets-sheet s Patented Apr. 12, 1949 UNITED STATES PATENT CFFICE ARCH AND WALL CONSTRUCTION Paul Wright, Birmingham, Ala. Application March 9, 1944, Serial No. 525,772

19 Claims. 1

This invention relates to arch and wall constructions, used for furnaces and for structures that are subjected to the action of heat.

This application constitutes -a continuation in part of my application led September 12, 1939, Serial No. 294,568 for Arch and Wall, now Patent 2,346,638, April 11, 1944.

An object of this invention, is to provide an arch or wall structure that is externally heated, whereby the temperatures of the structure itself, are varied by heat absorption means within the structure.

A further object is to provide an arch or wall structure that is constructed, in part, with plastic or castable material that is molded in place,

whereby said material incases a cushioning in sulation that surrounds tube elements which are arranged within the structure.

Another object is to provide a structure that is constructed with spaced tube elements arranged within said structure, said tube elements being surrounded with a cushioning insulation, which insulation is incased by firm blocks, which blocks hold plastic or castable material constructed there-between.

My invention further contemplates the provision of a composite wall construction with spaced tube elements, either in the form of separate tubes or as spaced coils of a single tube; and cooperating pairs of tube blocks incasing said tube elements which are surrounded with cushioning insulation interposed between said blocks and tube elements; moldable plastic or castable material occupying the space between the blocks on adjacent tube elements, whereby said blocks and moldable material form the refractory portion of said wall; and a back-up layer of hollow tile or brick masonry, that is retained in contact with said refractory portion by means of fasteners secured to said tube elements.

A still further object, is to provide a wall structure, which employs within it, tube elements shaped as a helix or as a spiral, thereby enabling the interior surface of said wall to be shaped to a contour.

In this description and the appended claims, the term tube elements is intended to cover separate tubes, or separate coils of a single coiled tube. v

The various features of novelty which characterize my invention are pointed out with particularity in the claims annexed to and forming a part of this specification. For a better understanding of` the invention, its operating advantages andv specific objects attained by its use,

reference should be had to the accompanying drawings and description in which I have illustrated and described preferred embodiments of the invention.

Of the drawings:

Fig. 1 is a cross-section of a structure utilizing moldable materials, as illustrating an irregular shaped arch of my invention, Whose tube elements are approximately parallel, yet said tube elements may be straight or curved.

Fig. 2 is a horizontal section of a structure partially made of moldable material, the view being taken on lines 2-2-2 of Fig. 3.

Fig. 3 is a vertical section and elevation view 0f Fig. 2 taken on lines 3-3-3.

Fig. 4 is Ia plan view of part of a curved structure that embodies the invention.

Fig. 5 is a Section on line 5-5 of Fig. 4, showing one form of the structure as made with its tube elements in helical form.

Fig. 6 is a section of a quadrant as taken on line 5 5 of Fig. 4, but utilizing plastic or castable materials that are molded in place.

Fig. 7 is a composite plan of a ilat structure embodyinng the invention and it provides tube elements in the form of spiral coils, the Views being partial top and sectional plans as taken on lines 1-1 of Fig. 8.

' Fig. 8 is a transverse sectional view of the structure of Fig. 7 as taken on lines 8 8, showing one arrangement of the spiral tube coils.

Fig. 9 shows composite views of a structure embodying the invention as having a conical shaped wall constructed with spiral tube coils, the yviews being a partial outer elevation shown in relation to the partial sectional elevation.

Fig. 10 is a sectional view of a spiral tube coil shown in its relation to the cushioning material and molded material, as taken on section |0-I0 of Figs. 7 and 9.

In the structure, embodying my invention illustrated in Fig. l, spaced tube elements I serve as structural members that are surrounded by a cushioning insulating material 2. This insulation 2 may be preformed, as for example as partial cylinders of any suitable materials having cushioning properties, such as, expanded mica compounded with a binder, asbestos fiber compounded, i'lber glass, or mineral wool. Such preformed cushioning insulation is temporarily held about the tube element with tie strings or Wires 3 that wrap as construction ties, preparatory to placing the moldable material 4. Other forms of insulation 2, such as a tape that is wrapped around the tube element, can be used, since. the

insulation is not limited by any practical substance that can serve as an insulating or cushioning material.

As an example, plastic refractory 4 is placed about the insulated cushioned tube elements as shown by Fig. 1. A severed parting or joint 5 facilitates placing the refractory in sections. This joint 5 also provides for expansion and contraction between the portions 4, since the cushioning material yields to expansive movement of portions 4, both transversely and longitudinally about tube elements I. This feature reduces cracking of the structure after it has been cured or burned in service. The tube elements may be flexibly held, and as one example, they may be arranged one horizontal tube element above another adjacent element, as in a wall.

An important feature of the insulation 2, is that it facilitates curing or suitably heating plastic 4 to give it a more rigid form. Thus tube element I is protected against overheating, since excessive heating could be detrimental to the tube element. And, since a cooling medium is at times employed within tube elements I, `obviously insulation 2 shields the contacting plastic 4 against giving up its heat to the tube element I; whereby the portion of plastic near the tube elements can absorb heat, or, the insulation prevents cooling from the tube element, to a degree that would prevent a set-up of the plastic adjacent the tube elements.

This construction of Fig. 1 advantageously accommodates an arranged spacing of the tube elements I, whereby the outer surfaces of an arch may be made with plane sides or with sides curved, as may effect an economy of the materials and also suit special heat reiiecting properties related to radiation, of the arch.

The structure of Fig. 1 can be used as an arch arranged in any position, as for example, the roof of a furnace, a baille arch within a furnace, or as a partition or wall within the furnace. The shape of the joints 5 can be arranged in a manner convenient for construction and to relieve the stresses due to expansion caused by heatingl of parts 4. The tube elements I may be straight or curved, and in either form the elements are approximately parallel.

Another important feature of the invention is gained by utilizing a tube covering 2 of a character that has insulating properties, since my construction facilitates the scope or degree of insulation that can be used about the tube, whereby the rate of heat absorption by a cooling medium within the tube element, can be varied.. Furthermore, with a proper thickness of insulation 2 and the degree of its insulating value being made suitable, the average temperature within the Fig. 1 structure can be varied by a change in flow of a cooling medium thru the tube elements I.

One practical advantage of the invention resides in the construction of a furnace which has walls and roof of Fig. 1, whereby the temperature of the atmosphere within the furnace can be influenced by the variation of the furnace wall temperatures, which are varied independently of the heat input into the furnace. Heretofore it has been customary to endeavor to control temperatures of a furnaces atmosphere, by a regulation of the heat input, as by control of fuel or delivery of heat in varied quantities into the atmosphere of the furnace itself. My invention provides a new feature, that the atmosphere ofthe furnace can be varied by a cooling medium within the wall as of Fig. 1, independentlyof the Icharge 4 or material to be heated, as for example within a heat treating furnace, also independently of the firing of the furnace. Conversely, a heating medium may be employed Within the tube elements, as a means effecting changes of wall temperature, as for example in utilizing steam.

In utilizing plastic materials, it is customary to pack same into place, by applying portions that gradually adhere to build up the thickness required. This thickness is usually limited to a range of heat penetration that will cure or solidify and make a rm structure of the entire plastic.

Whereas Fig. 1 and the other drawings, show cylindrical tube elements, the invention is not limited to the shape of the tube element, acting as a support and as a conveyor of a fluid medium.

But myinvention is not limited to plastic materials, since castable materials are practical. Castable refractory, for example, is poured in place and thereafter sets up in a solid form, without the necessity of applying heat for curing it, as is required for plastic. Also castables customarily do not have as. high. a heat range permissible as for plastics and my invention enables the control of the wall temperatures of castable material so esto facilitate its use. I classify both plastic and castable refractories, as being moldable refractory materials.

In Figs. 2- and 3, the construction of Fig. 1 is modified by using rm blocks that surround the cushioned tube element. Tube elements I of Figs. 2 and 3, are insulated and cushioned by a material I that is interposed between the tube element `I and blocks 8 that are recessed as shown.

- As one example of my invention, the blocks 8 are shaped as shown by Figs. 2 and 3 so as to practically surround material 1, which cushioning may not be so rm as the preformed material 2 of Fig. 1. This permits pounding the plastic 4 like that in Fig. 1, into its place of Fig. 2 without distorting the cushioning 'I which is protected by refractory blocks 8 that are previously kiln burned and suitable to withstand handling and suitable to. retard passage of heat thru same. Asv a means of providing a cheap but entirely practical cushioning 1., I can use granulated mineral Wool as the material 'I of Figs. 2 and 3, also I can quickly pack it hand-'tight into the recess of the blocks 8, as set about the tube element I. Also an improvement resides in first using the annular washer or stop 6 that surrounds the tube element I. just above the lower blocks 8 or at the bottom of the recess of blocks 8 that` are to be filled with granular mineral wool 'I, from above. Also this washer 6 may be a cement that is buttered on the blocks 8 as they are placed about the tube element I., which cement 6 sets so as to resist packing of the granular material 'I into the recess beyond and beneath. Thus the blocks 8 may be centered around tube element I by means of stop 6 described, and any suitable material that will resist hea-.t of the installation, can be used.

Probably less skill is required to build the construction of Figs. 2 and 3 than of Fig. 1; but I do show an outer closure III in Fig. 2, which closure can be an insulating board,Y used to back up the moldable material 4. Also in lieu of the board I0. a common tile or brick masonry wall could bev used. The features claimed for the wall of Fig. 1, are equally advantageous for the wall of Fig. 2, as regards `the advantage of uniformly curing or heating the plastic. refractory as held by blocks 8 and, said refractoryv 4 can be. shaped as shown by Fig. 2 soy as to save in its thickness or to provide an irregular'or curved refiecting inner surface next to ythe iire. Likewise the constructions of Figs. 4,

and 6 provide a similar curved reflecting inner 'surface next to the fire. I do not limit blocks 8 to the speciflc shape of Figs. 2 and 3, since their shape or contour may be varied'so as to suitably l.

fractory, since other firm materials in block form serve for the invention.

The construction of Figs. 2 and 3 enables usingblocks 8 that may vary some from their intended .manufactured size, yet the finished construction is true to specified outer shape and it is arranged so as to provide for expansion and contraction, in the manner of Fig. 1 constructions.

Arches and walls that endure severe service should be repairable quickly, so save outage time and expense. The construction of Figs. 1, 2, and S'permits tearing out parts of the plastic or castable 4, without necessarily damaging the insulation 2 and particularly is this an advantage of the Figs, 2 and 3 structures that employ firm blocks 8 to protect and shield the cushioning 1 surrounding the tube element I. In Figs. 2 and 3, the use of blocks 8 with tube elements! can be employed with any suitable cushioning or insulating materials which were described as being usable for Fig. 1 constructions. The blocks 8 are separated by an appropriate expansion joint 5 that is similar to the joint 5 of Fig. 1. The blocks 8 can lbe temporarily held with tie wires3 or string.

wound around same and if need be, the joint 5 can be maintained parted during construction by a thin spacer of paper board or any suitable resilient substance 9.

By Figs. 1, 2 and 3, I have shown that the tube elements I, act as structural members, about which the arch or wall is constructed and sustained. In various positions, the tube elements I act as supporting members or as binders for the arch or wall and such binder tube elements usually must be stiff or resistant to flexure. In some arches and walls of this invention, I use tubes without circulating a cooling medium through same. In others Where a cooling medium is used, I prefer to employ air, gas, oil, steam or water, in various structures and I therefore use the term cooling medium as a general description for any of these. But I do not limit the kind of cooling medium to those named, since there are other heat absorbing substances that are usable as a cooling medium, also suitable to my invention. f

The constructions `of Figs. 4, 5 and 6 are like Figs. 2, 3 and 1 respectively, and curved tube elements -lc are used and the cushioning insulation 2c is rshaped to t. Likewise in Figs. 4 and 5, blocks 8c are provided with curved recesses that `suit the tube element Ic as cushioned and insulated. The helical tube element Ic advantageouslyserves as a binding ring or vretainer rfor the vassociated parts 2c and 8c, functioning somewhat' like a hoop. The shape of blocks Bcmay be varied'so as to suitably contact and engage, the moldable materials 4c, as held in place by said blocks 8c.

Thusv ya hollow cylindrical structure of Fig. 4. can be used as a round furnace chamber. Such a furnace chamber can be arranged or positioned with the axis of its cylinder in various positions, since the curved tube elements Ic hold the assembled parts 'lc and 8c and 4c'in sustained'formi vWhere the tube elements of Fig. 1 are curved andthe elements are approximately parallel, the construction is similar to that of Figs. 4 and 6. Furthermore, the'structures of Figs. 4, 5 and 6 readily accommodate yexpansions of the parts comf prising same, as are caused by their being heated. For example if tubeelements lc are maintained at approximately uniform temperature, the parts 8c and 4c vthat absorb heat, may expand independently of tube elements Ic since the joints 5c 'andthe cushioning materials 2c or 1c provide for expansive movement. The preformed material 2 of Fig. l and 2c of Fig. 6, is usable with the blocks 8 of Fig. 2 and 8c of Fig. 5, as the invention isl not limited to such combinations. Furthermore, the Joints of Fig. 5 between blocks 8c and Fig. 6 between portions oi.' 4c material, Isuch are contact joints without an intervening space between portions as for joint 5c of Fig. 4.

Another use of tube elements shaped in spiral form, provides for constructing furnaces that have an approximately conical inner surface or a surface that is shaped to a contour. Also the axis of the spiral tube elements may lie in approxmately a plane, so as to provide a flat structure, utilizing the cushioning insulation and moldable refractory. For example, the construction of Figs. 'I and 8, employs spiral tube coils that lie approximately in a plane and the construction of Fig. 9 employs spiral tube coils as suiting a wall whose surface approximates a conical contour. The upper view of the tube coils is of Fig. 9 is similar to the view of tube coils I s in Fig. '7. Fig. 10 shows for example preformed cushioninnginsulation 2s -about coil is and providing an open joint 5s between moldable material 4s on the one side and the opposite side has the joint filled with a resilient substance 9s. In the several figures, like numerals represent like materials.

My invention provides arch and wall constructions whose exposed surfaces will withstand re on both sides; also it provides a structure that may be internally heated or cooled by a medium passed thru its tube elements, whereby the stresses due to expansive movements of its structural parts are relieved.

While in accordance with the provisions of the statutes I have illustrated and described herein the best forms vof the invention now known to me. those skilled in the art will understand that changes may be made in the form of the constructions disclosed without departing from the spirit of the invention covered by my claims, and that certain features of my invention may sometimes be used to advantage without a. corresponding use of other features.

I claim:

1. A wall structure comprised of a plurality of substantially parallel tube elements, a layer of cushioning insulation in contact with and surrounding each of said tube elements; solid molded refractory sections, between and in contact around said cushioned insulated tube elements, each section substantially abutting adjacent the cushioning insulation.

2. Animperforate structure subjected to the action of heat, said structure comprised of a row of substantially parallel tube elements, a layer of preformed cushioning material provided in sections as substantially surrounding each tube element; and means comprising solid moldable material Ain sections between and contactual 'around said cushioned tube elements thus providing expansion joints between said sections,

anonime 7 .ssimioints being transversely @and longitudinally ,adacent the *itube elements Lof Tsaid structure.

13. A heat `resisting :structure :subjected exterf nelly ato zflre, :said structure --comprised tof .a iplufrailty eof `spaced tube elements .'exiblyheld nas enabling the expansion :and contraction of said rstructure; A:a llayeraof Ycushioning.materiau-n .Iconta'ct with :and :surrounding `each -of said tube elements; A a plurality of spaced :rows of blocks, each-fo'fvsaid rows including pairs of'contacting :blocks ,provided `with recesses and substantially surrounding one of said cushioned :tube elements and-means to bind isaidblocks iniplace; 4andmeans comprising #sections voi" vmoldable imaterial in- Vmarcily and outwardly 'between and 'contactually Iaround said lrows of blocks, and -abutting oints between sections.

4. In astructure of fthe character fdescribed, a plurality of spaced t substantially parallel 'tube elements, :a layer-ofinterposed insulatingmaterial `held-inicon-tact with land surrounding'each-offsaid tubeefelements by .means of co-operatingl pairs of .inca-sing tube vblockaand each of rsaid blocks hav- -ln'ga recess sthereinpartially embracingits assofciatedinsulated tubeelement; `means yto `bindsaid .pairszofeincasing blocks labout the insulated tube .felementa andzisolid moldable material in sections extending between and -rcontactually :around :the :said ,pairs :of incasing blocks and with Vprovision lof 'expansion joints therebetween, adjacent :the-j oints betweenrsaid pairs of blocks.

5. :A lstructure comprising .a :plurality off-subyistantiallyparallel tube elements, a layerof'cushinning material in contact with :and 4surrounding each of .-s'aid'ztube elements; fa plurality of spaced rows :0i: blocks leach-.offsaid rows including pairs of .icontactingtblocks 'provided y.with `recesses .and surrounding `one fo'f said cushioned tube elements; and molded material provided betweentheblo'cks linfoneoi said rows :and the blocks in .anadja'cent from-,to :holdsaid blocks in `place "onJsaid `cushioned tube elements, thezassembled structurebeing im- ;perforate. Y

.6. |`fInia structure `of the `character described, a plurality of spaced substantially parallel tube fel'ements, co-operating pairs of tube blocks ,incasing :said iltube elements, .each block `having a :recess therein lpartially embracing rits "associated tube element, cushioning .material interposed .between -thefblocks .and 'the tube elements; and .molded 'rei `fractory material solidly contactual between :said blocks on .adjacent tube elements, whereby said cushioning material is protected by lits .incasing blocks.

Astructure 'of 'the `character described 'that comprises in combination, a tube element'substantially helical in form, a layer of cushioning material in contact with and surrounding said `tube 'element; co-operatingpairs of tube `blocks incasing said tube element, -leac'h `bloclr "having la 'recess Vtherein partially Vembracing V.its associated portion of the `cushioned tubeelement; andmate- `rialinzsections Ithat extend Varound and between -salid blocks. y

8. In arch and wall construction of the character describedfxedly spacedsubstantially` parallel superano-operating .partszo'f eushioninginsulators, each insulator :par-t 'having a recess therein ,par-

ftially embracing its `associated 'tube 'Sand ities .to

.between :said portions, `with the :partings adjacent ythe :insulators -.9. In a 'furnace, a .structure that :comprises a yplurality .fof substantially parallel tubes, a layer :of .insulation in contact with 4and `surrounding said rtubes; azplurality of :spaced rows of blocks, each fof A:said rows Vincluding pairs @of contacting iblocks provided .with :recesses and substantially vsurroundingfone .of-said insulatedltubes and means toebind -said :blocks in place andplasticl refractory between each of said rows `of vblocks.`

.in-a :structure of the'char-acter described, :a row :'dfwspaced :substantially parallel tubes, cofoperatingipalrs lof ytubeblocks incasing said tubes, each :block having .a recess therein partially em- -bracing .its associated .tube and said blocks positioned aboutsaid 1tube :with annular 4washers and -feushioningmaterial interposed'between the blocks :and itubes; means t'ozbind said blocks in place, iandmoldable material 'between and substantially surrounding said blocks, athe :assembled structure .forming "a wall whose mol-dable material vis lreipairable.

Infarch and wall construction of the chariaeter zd-escribed, `'a plurality `oi"1substantiallyparal vlel Vtubes, alayer Hof cushioning `material held in .contact wthandsurrounding each of said tubes; plurality :offspaoed rows of blocks `eachof said 'rows 'including :pairs vof contactinglblocks pro- -vi'ded fwith recesses :and substantially surrounding @onef'of saidtubes.; vties to bindsaid blocks in place; rand @moldablerm'aterial Ibetween and 4substantially .surrounding said-blocks and said molded material :provided with joints adjacent 'the joints between `@said `blocks.

.in .fa wall `,whoseinterior surface approximates a contour, approximately :parallel 4tube ele- .ments :arranged in pairs and :a :layer of cushionfingzmaterialincontact'with and surrounding'each of said l:tube elements; :and solid .molded material iin .sections extending .inwardly rand outwardly .beitweenlandontactualaround said cushioned tube elements, thus bounding l`the interior and exterior A:surfaces .of fs'aid fwall, and the molded material divided 'byparting joints :adjacent the .cushioning maLtelal,

1.13. :Ailatrstructurecomprised oftl spiral tube element, allayer :of cushioningimaterial .in .contact 'wi'th `and fsurrounding said :spiral Vand molded lni'a'terial'infsections extendingisolidly between and .cont'antua'lly around ithe `coils fof -saideus'hioned :spiral itube element, and L abutting 'joints 'between sections.

14. 'In a "wall whose interior lsurface approximates a conical contour, a spiral .tube `element :provided with a layer of lcushioning:material in contactfwith .andesurroun'ding the tube element for said spiral.; :and :molded material in solid sections :between and contactually surrounding the :icoilseofsaid cushioned spiral, thus bounding the interior :and exterior surfaces of said wall, and "abutting joints :between sections.

.15. A.;structure subjected .to the actionvof heat, comprised lof y'tube :elements I.providing :means of heat transf-er, Athrough va. .layer of cushioning .material 1 in` contact-with'rand surrounding .each .of

:said'itu-bezfelements. and molded `material :in contacting portions solidly between andsubstantially ssurrounding `:said .adjacent .cushioned 4`tube elements, 'with abutting .joints between portions.

^ 16..,Azstructureisubjected tothe action of heat, .comprisedioftube elements providing means of heatxtransfer, La layer :of cushioning material in contact with 'andsurrounding eachof said tube elements, i a plurality of spaced :rows of blocks each of said rows comprising pairs of cast blocks with recesses and surrounding in contact one of said cushioned tube elements, means binding said cast blocks about said cushioned tube elements; and molded material in sections that inwardly and outwardly are solid between, and contactual around said rows of blocks, and abutting joints between sections.

17. A structure subjected to the action of heat, said structure comprising a plurality of spaced tube elements suitable for conveying a medium transmitting heat; a layer of cushioning material yieldingly surrounding and contacting each of |said tube elements; and rigid material constructed between and solidly surrounding in sections each cushioned tube element, and parting joints between said rigid sections, suitable for accommodating expansion.

18. Awall of the character described comprised of, a plurality of spaced tube elements, a layer of contacting cushioning material surrounding each of said tube elements; and means comprising solid moldable material in sections inwardly between and contactually surrounding each of the `cushioned tube elements, and a back-up closure for said wall, outwardly against which said material bears, with abutting joints between sections.

19. In arch and wall construction of the character described, a tube element suitable for temperature changes, a. layer of contacting insulation suitable for said temperature changes and yieldingly surrounding and contacting said tube 10 element; and sections or rigid material substantially surrounding and contacting said insulated tube element, with parting joints transversely and longitudinally adjacent the insulated tube element.

PAUL WRIGHT.

REFERENCES CITED The following references are of record in the le of this patent:

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